Two of the Moto-Bikes that I restored were missing the headset plug. The plug is plastic and held in place with rubber that is compressed by tightening a screw on the top of the plug.
Using an original plug as a model, I made a replacement from 1″ delrin rod, rubber tubing, a tee nut and a screw. The delrin plug was turned on my lathe.
Before and after photos of the triple clamp and handlebars.
The original chrome rear fender was missing. I found a 30 year old front fender from a bike with 26″ wheels and trimmed it to fit. It’s not a perfect replica, but a decent looking substitute.
The original paint metal chain guard was missing. I found a replacement with a similar basic shape, trimmed it to be a close match and painted it satin black like the original. The brackets were fabricated from sheet metal and plated.
After partially reassembling the bike, I discovered the rear wheel was not aligned with the frame or front wheel. I removed the swingarm and bent each of the wheel stays about 3/8″. The photos show before and after this “adjustment”.
Stripped and bead blasted all of the painted parts to prep them for primer. After the gray primer, 3 coats of single stage automotive paint was applied. On the frame and swingarm an additional coat of white sealer/primer was applied before the yellow. Handlebars and top triple clamp are satin black. Seat and bottom fork clamp are gloss black. Frame and swingarm are Yamaha yellow.
Disassembled the rear shocks, bead blasted the aluminum and repainted the springs.
This Moto-Bike had been ridden a lot with the crank loose. As a result, the right crank arm had worn a hole through the swing arm. I repaired the hole by making a patch from a piece of tubing. The patch was welded in place and filed flush.
The seat on this Moto-Bike is in considerably worse shape than the first Moto-Bike. Fortunately the metal on the seat pan is thin and easy to bend back into shape.
